Object loading device

ABSTRACT

An object loading device includes an object conveyor for conveying objects to a hopper at one end of the object conveyor. A container conveyor conveys containers to a position underneath the hopper. Objects are discharged from the end of the object conveyor onto closed shutters in the hopper. A bottom plate elevator lifts the bottom plate of a container under the hopper to an upper position. The shutters slide open and the objects gently drop onto the elevated bottom plate of the container. The shutters are then closed and bottom plate elevator lowers the bottom plate to the bottom end of the container. The container conveyor then moves the container with the objects away from the position underneath the hopper. A further embodiment includes padded buffer rollers between which objects pass on their way to the container.

BACKGROUND OF THE INVENTION

The present invention relates to an object loading device for loadingobjects into a container.

Referring to FIG. 12a, a conventional object loading system 10 forloading objects into a container has an object conveyor 2 for conveyingobjects 1 toward a frame-shaped hopper 3 in an object conveyingdirection indicated by arrow 6. Hopper 3 is located at a forward end ofobject conveyor 2. A container conveyor 5 conveys containers 4 to aposition underneath hopper 3. Container conveyor 5 passes below hopper3. Container conveyor 5 conveys containers 4 in a container conveyingdirection indicated by arrow 7. The container conveying direction issubstantially perpendicular to the object conveying direction. Eachcontainer 4 is formed in the shape of a box having continuous side wallswith a bottom plate and an open top.

The process of loading objects into container 4 begins by conveyingcontainer 4 to a position underneath hopper 3 on container conveyor 5.Objects 1 are conveyed toward hopper 3 by object conveyor 2.

Referring now to FIG. 12b, at the forward end of object conveyor 2,objects 1 fall off of object conveyor 2, traveling directly throughhopper 3.

Referring now to FIG. 12c, objects 1 fall onto a bottom plate 8 ofcontainer 4.

Referring to FIG. 12d, upon completion of loading objects 1 intocontainer 4, container conveyor 5 moves container 4, which now containsobjects 1, to an area remote from hopper 3 while bringing a newcontainer 4 to the position underneath hopper 3, thereby preparing newcontainer 4 for a next cycle of object 1 loading.

In the above described process of conventional object loading system 10,objects 1 fall directly from object conveyor 2 onto bottom plate 8through hopper 3. Objects 1 are discharged from object conveyor 2 by theconveying motion of object conveyor 2. Objects 1 fall a long distancefrom a conveying surface of object conveyor 2 to the bottom plate ofcontainer 4. For these reasons, objects 1 tend to crash onto the bottomplate of container 4 or other objects 1 already placed thereon. Such animpact often causes damage to objects 1, such as, for example, dents andtears in cases where object 1 is a box or a carton, and breakage incases where object 1 is a bottle or other glass or plastic container.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of the present invention to provide an object loadingdevice which overcomes the problems of the prior art.

It is a further object of the present invention to provide an objectloading device which is capable of lowering objects slowly onto thebottom plate of a container, thereby protecting the objects from damageand breakage.

It is another object of the present invention to provide an objectloading device with cushioned surfaces which reduce the force of impactof objects which are to loaded.

Briefly stated, an object loading device includes an object conveyor forconveying objects to a hopper at one end of the object conveyor. Acontainer conveyor conveys containers to a position underneath thehopper. Objects are discharged from the end of the object conveyor ontoclosed shutters in the hopper. A bottom plate elevator lifts the bottomplate of a container under the hopper to an upper position. The shuttersslide open and the objects gently drop onto the elevated bottom plate ofthe container. The shutters are then closed and bottom plate elevatorlowers the bottom plate to the bottom end of the container. Thecontainer conveyor then moves the container with the objects away fromthe position underneath the hopper. A further embodiment includes paddedbuffer rollers between which objects pass on their way to the container.

According to an embodiment of the present invention, there is provided,an object loading device for loading objects into containers with anopen top, comprising: an object conveyor, a hopper at an end of theobject conveyor, the hopper receiving objects conveyed by the objectconveyor, at least one flap movably mounted on a bottom portion of thehopper, the flap being moveable between a closed position and an openposition to selectively hold and release the objects in the hopper,respectively and means for positioning a container below the hopper toreceive the objects.

According to another embodiment of the present invention, there isprovided, an object loading device for loading objects into a containerhaving an open top, comprising: an object conveyor, a hopper mounted atan end of the object conveyor, the hopper receiving objects conveyed bythe object conveyor, a first roller and a second roller rotatablysupported along a bottom of the hopper, the first roller and the secondroller having a cushioning material on exterior surfaces of the firstand the second rollers, a distance between the first and second rollersbeing large enough for the objects to pass between them and a containerconveyor.

According to another embodiment of the present invention, there isprovided, an object loading device for loading objects into containershaving a moveable bottom plate and an open top, comprising: an objectconveyor, a hopper mounted at a forward end of the object conveyor, thehopper receiving objects conveyed by the object conveyor, a containerconveyor, means for holding a container on the container conveyor in areceiving position aligned below the hopper and a lifting mechanismwhich lifts the moveable bottom plate toward the hopper when thecontainer is in the position aligned below the hopper.

According to another embodiment of the present invention, there isprovided, a method of loading objects into a container comprising thesteps of: transporting the objects to a hopper, retaining the objects inthe hopper, positioning the container underneath the hopper, raising abottom plate of the container toward a raised position underneath thehopper, releasing the objects through an opening on the bottom of thehopper onto the bottom plate in its raised position, lowering the bottomplate back down to a bottom of the container.

According to still another embodiment of the present invention, there isprovided, a method of loading objects into a container comprising thesteps of: positioning the container underneath a hopper, raising abottom plate of the container toward the hopper, transporting objects tothe hopper, transporting objects through cushioned rollers in the hopperand lowering the bottom plate to a bottom of the container.

The invention according to one embodiment discloses an object dumpingsystem for dumping objects into a box-shaped container with an open top,the object dumping system includes an object conveying means forconveying the aforementioned objects. A hopper at the end of the objectconveying means receives the objects dumped from the object conveyingmeans. Shutters at the bottom of the hopper are opened and closed duringthe cycle. A container conveying means conveys the containers to aposition aligned underneath the hopper.

The invention according to another embodiment discloses an objectdumping system for dumping objects into a box-shaped container with anopen top. The object dumping system has an object conveying means forconveying the aforementioned objects. A hopper at the end of the objectconveying means receives objects dumped from the object conveying means.A first buffer rotor having a cushioned buffer portion therearound isrotatably supported at the inner bottom of the hopper, at a locationnear the end of the object conveying means. First buffer rotor extendsparallel to the end of the object conveying means. A second buffer rotoralso having a cushioned buffer portion therearound is rotatablysupported at the inner bottom of the hopper, at a distance from thefirst buffer rotor sufficient to permit the objects to passtherebetween. A container conveying means conveys the aforementionedcontainers to a position underneath the hopper for receiving the objectswhich pass between the first and second buffer rotors.

The invention according to another embodiment includes a container witha bottom plate that moves upward to receive the objects without theobjects falling a substantial distance when the container is at aloading position. Upon completion of loading, the bottom plate movesdownward into position in the container, lowering the objects into thecontainer without dropping them. The container is moved away from theloading position by a container conveyor, while a new container is movedinto the loading position.

According to an embodiment of the invention, objects discharged from anobject conveying means first fall a short distance upon shutters at thebottom of a hopper. The shutters are gently opened and the objects falla short distance into a container. In this manner the objects areprotected from physical damage because the impact of a direct dischargefrom the conveying means to the container is reduced.

According to another embodiment of the invention, objects dischargedfrom an object conveying means contact first and second buffer rotors. Acushioned exterior of the buffer rotors reduces the impact of theobjects onto the buffer rotors. The objects then fall a short distancefrom the buffer rotors into a container. In this manner the objects areprotected from physical damage because the impact of a direct dischargefrom the conveying means to the container is reduced.

According to another embodiment of the invention, a bottom plate of acontainer conveyed to the position underneath a hopper is raised by anelevating means. Objects in the hopper at the end of the objectconveying means are released onto the bottom plate of the container. Thedrop distance of the objects from the hopper to the bottom plate of thecontainer is greatly reduced because the bottom plate is raised. Theobjects are protected from damage because the reduced distance lowersthe force of impact on the objects hitting the bottom plate of thecontainer. After all objects are loaded onto the bottom plate, thebottom plate is lowered into the container and the container istransported away from the hopper.

The above, and other objects, features and advantages of the presentinvention will become apparent from the following description read inconjunction with the accompanying drawings in which like referencenumerals designate the same elements.

BRIEF EXPLANATION OF DRAWINGS

FIG. 1a shows an object loading device according to an embodiment of theinvention at the beginning of a loading cycle.

FIG. 1b shows the object loading device of FIG. 1a with the objectsloaded in the hopper.

FIG. 1c shows the object loading device of FIG. 1a with the shutterspartially opened.

FIG. 1d shows the object loading device of FIG. 1a with the shuttersfully open and objects on the bottom plate of container.

FIG. 1e shows the object loading device of FIG. 1a with the bottom plateof the container being lowered with objects in the container.

FIG. 1f shows the object loading device of FIG. 1a with the bottom plateof the container at the bottom of the container.

FIG. 1g shows the object loading device of FIG. 1a with the objects inthe container and the shutters closed.

FIG. 1h shows the object loading device of FIG. 1a with the containerholding the objects just loaded being conveyed away and a new containerbeing conveyed underneath the hopper ready for another load of objects.

FIG. 2 is a sectional view of the object loading device of FIG. 1ashowing the end of the object conveying means with the hopper.

FIG. 3 is a front view of the object loading device of FIG. 1a.

FIG. 4 is a top view of the sectional view of FIG. 2

FIG. 5 is a front view of a container conveyor of the object loadingdevice of FIG. 1a for conveying containers.

FIG. 6 is a top view of said container conveyor.

FIG. 7 is a top view of a container.

FIG. 8 is a front view of the container of FIG. 7.

FIG. 9 is a sectional view of the container of FIG. 7 taken along theline X--X.

FIG. 10 is a sectional view of an object loading device according toanother embodiment of the present invention.

FIG. 11 is a top view of the object loading device of FIG. 10.

FIG. 12a shows a conventional object loading system at the beginning ofa loading cycle.

FIG. 12b shows the object loading system of FIG. 12a with objectsfalling from an object conveyor directly into a container.

FIG. 12c shows the object loading system of FIG. 12a with the objectsloaded in the container.

FIG. 12d shows the loading system of FIG. 12a with a container conveyingmeans removing a loaded container from the conveyor and moving an emptycontainer toward the container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1a, an object loading device 100 includes a containerconveyor 24, for conveying a container 11 to a object loading positionaligned underneath a hopper 23. Container conveyor 24 moves container 11in a container conveying direction indicated an by arrow 105. An objectconveyor 21 conveys objects A toward hopper 23. Object conveyor 21discharges objects A into hopper 23. Objects A enter hopper 23 atsubstantially the same level as object conveyor 21, whereby objects Aare not subjected to a substantial drop or fall. Object conveyor 21conveys objects A in an object conveyor direction indicated by arrow106. Hopper 23 is located at a forward end of object conveyor 21.

Hopper 23 includes shutters 22 mounted along a bottom portion of hopper23 for holding and releasing objects A. Container conveyor 24 includes abottom plate elevator 25 for lifting a bottom plate 13 of container 11.Bottom plate 13 is movable in a vertical direction from the bottom endof container 11 to the top end of container 11.

To load objects A into container 11, container conveyor 24 first movescontainer 11 to object loading position underneath hopper 23. Althoughcontainer conveyor is shown as a belt, the preferred embodiment usesrollers having a space underneath hopper 23 which provides bottom plateelevator 25, mounted below container conveyor 24, access to bottom plate13 of container 11, which rests on top of container conveyor 24.

Referring to FIG. 1b, bottom plate elevator 25 lifts bottom plate 13, ofcontainer 11, to a top end of container 11.

Referring to FIG. 1c, shutters 22 begin to open by sliding out fromunder the side panels of hopper 23. This sweeps objects A onto bottomplate 13.

Referring to FIG. 1d, shutters 22 slide completely under the side panelsof hopper 23. Objects A are blocked from traveling with the shutters bythe side panels of hopper 23. When the shutters slide completely outsideof hopper 23, the bottom of hopper 23 is open and all objects A areshifted to bottom plate 13.

Referring to FIG. 1e, once objects A are on bottom plate 13, bottomplate elevator 25 lowers bottom plate 13 to the bottom end of container11.

Referring to FIG. 1f, bottom plate 13 is completely lowered to thebottom of container 11 with objects A.

Referring to FIG. 1g, once bottom plate 13 is completely lowered,shutters 22 are slid back into place, ready to retain the next load ofobjects A from object conveyor 21 in hopper 23.

Referring to FIG. 1h, container conveyor 24 moves container 11 away fromthe position underneath hopper 23 and moves a new container 30 to theobject loading position underneath hopper 23 in preparation for the nextload of objects A.

In a preferred embodiment of the invention, objects A begin loading intohopper 23 whether or not container 11 has reached alignment below hopper23. This permits substantially continuous loading of objects A withoutwaiting for the illustrated alignment of container 11 and hopper 23.

Referring to FIG. 2, object conveyor 21 is a belt conveyor using anendless belt 34. A pair of conveyor frames 31 are mounted along thesides of endless belt 34. Rollers (not shown in FIG. 2) are rotatablysupported between conveyor frames 31 at the base end of the objectconveying path. End rollers 32 and 33 are positioned near the forwardend of the object conveying path. End rollers 32 and 33 are alsorotatably supported between conveyor frames 31.

Endless belt 34 wraps around the rollers at the base end of the objectconveying path and around end rollers 32 and 33. Endless belt 34 has ahorizontal portion 34a and an inclined portion 34b. Inclined portion 34bextends between end rollers 32 and 33. Horizontal portion 34a extendsfrom end roller 32 to the base end of the object conveying path.

Conveyor frames 31 are supported by legs 35. Each conveyor frame 31 hasa pair of guide plates 36 and a pair of supporting plates 37 both ofwhich project upward along the sides of conveyor frame 31. Supportingplates 37 are closest to the forward end of the object conveying path.Hopper 23 is fixedly connected to the front of supporting plates 37.

Shutters 22, mounted at the bottom of hopper 23, include shutter plates61 which face the bottom of hopper 23. Shutter plates 61 are inclineddownward in the object conveying direction. Each shutter plate 61 hasL-shaped guide projections 62 and 63. Guide projection 62 projectdownward from the end of shutter plate 61 adjacent to conveyor 21. Guideprojection 63 project upward from the other end of shutter plate 61.Each shutter plate 61 also includes a shutter plate cushion 64 made of asoft and pliable material, such as for example, a sponge or foam rubber,which is attached to an upper surface of shutter plate 61.

A hopper frame 41 supports hopper 23. A pair of long frame portions 42are mounted substantially perpendicular to the object conveyingdirection. A plurality of legs 44 are attached to long frame portions42. Each long frame portion 42 of hopper frame 41 has guide rails 65 and66 for respectively receiving guide projections 62 and 63 ofcorresponding shutter 22. Guide projections 62 and 63 are slidablyfitted in respective guide rails 65 and 66.

Container conveyor 24 includes a pair of conveyor frame members 71mounted parallel to each other and perpendicular to the object conveyingdirection. A pair of auxiliary frame members 74 are mounted on crossjoints 72 below hopper 23. Cross joints 72 connect conveyor framemembers 71. Each auxiliary frame member 74 faces an inner surface of acorresponding conveyor frame member 71. A plurality of short rollers 78are rotatably mounted between each auxiliary frame member 74 and theinner surface of the corresponding conveyor frame member 71. Shortrollers 78 are arranged along the container conveying direction.

Bottom plate elevator 25 includes an elevating board 101 mounted betweenauxiliary frames 74 at the object receiving position. An elevator aircylinder 102, mounted under conveyor frame members 71, raises and lowerselevating board 101 above and below the top surface of short rollers 78.When container 11 is positioned above bottom plate elevator 25, themovement of elevating board 101 raises and lowers bottom plate 13.

Referring to FIG. 3, long frame portions 42 of hopper frame 41 areconnected by a plurality of cross joints 43. The rectangular frame ofhopper frame 41 is substantially parallel to horizontal portion 34a ofendless belt 34.

A pair of shutter air cylinders 67 are mounted on cross joints 43 atboth lateral sides of hopper frame 41. Air cylinders 67 push or pulloperation rods 68 to close or open shutters 22, respectively.

Referring to FIG. 4, hopper 23 is U-shaped. A pair of side panels 51extend parallel to both sides of conveyor 21. An end panel 52 faces theend of the object conveying path of conveyor 21. Of the two ends of eachside panel 51, the end adjacent to conveyor 21 is attached to supportingplate 37, while the other end is attached to long frame portion 42 ofhopper frame 41 by fittings 53. A hopper cushion 54 covers the entireinner surface of side panels 51 and end panel 52. The lower end of eachside panel 51 inclines downward in the direction objects A are conveyed.

Objects A are transported from conveyor 21 through a chute 55 ontoshutters 22. Chute 55, mounted between side panels 51 of hopper 23, isinclined downward in the object conveying direction of objects A.

Referring to FIG. 5, a box 75 is mounted under one end of containerconveyor 24. Legs 76 and 77 support box 75 and the portion near theother end of container conveyor 24, respectively.

A plurality of long rollers 79, arranged along the direction in whichcontainers are conveyed, are rotatably mounted between conveyor framemembers 71 where no auxiliary frame members 74 are mounted betweenconveyor frame members 71 on container conveyor 24.

A pulley 81 is rotatably mounted at each end of object conveyor 24.Running along the inner surface of corresponding conveyor frame members71, an endless V-belt 80 is wrapped around pulleys 81. Endless V-belt 80is also supported on a plurality of upper side guide pulleys 82 disposedbetween short rollers 78 and long rollers 79. A tension pulley 83 belowconveyor frame members 71 maintains a required tension on V-belt 80.Underside guide pulleys 84 support the return run of endless V-belt 80.Guide rollers 82 press the upper portion of V-belt 80 against theunderside of rollers 78 and 79 so that rollers 78 and 79 rotate whenV-belt 80 is revolved about pulleys 81.

A motor 85, mounted in box 75, rotates one of pulleys 81. The rotationof pulley 81 causes V-belt 80 to revolve about pulleys 81. Movement ofthe upper run of V-belt 80 rotates rollers 78 and rollers 79. Acontainer resting on top of rotating rollers 78 and 79 moves in thecontainer conveying direction.

A next container stopper 86 is located immediately behind the objectreceiving position of container conveyor 24, in the transport directionof containers 11. A next container air cylinder 87 raises and lowersnext container stopper 86 above and below the container conveyingsurface. Next container air cylinder 87 is attached to the underside ofconveyor frame members 71.

A downstream stopper 88 at the downstream side of (ahead of) the objectreceiving position stops the current container 11 in the objectreceiving position. A downstream air cylinder 89 raises and lowersdownstream stopper 88 above and below the container conveying surface.Downstream air cylinder 89 is attached through a connecting member tothe underside of conveyor frame members 71.

An upstream stopper 90 clamps the upstream end of the one of containers11 positioned to receive the current load of objects. Upstream stopper90 is rotatably supported by a shaft 92 on one of the cross joints 72between a pair of supporting members 91. An upstream air cylinder 93rotates upstream stopper 90 between an up position, above the containerconveying surface, and a down position, below the container conveyingsurface. Upstream air cylinder 93 is also mounted on conveyor framemembers 71.

A guide rail 94 on an upper part of each conveyor frame member 71 guidesthe lateral sides of containers 11. First, second, and third detectingmeans 95a, 95b, and 95c are mounted immediately behind the objectreceiving position, at the downstream side of the object receivingposition, and at the end of the container conveying path, respectively.Detecting means 95a, 95b and 95c may be of the same or different types.In the preferred embodiment detecting means 95a, 95b and 95c arereflection type photo-sensors.

Referring to FIG. 6, plate-shaped cross joints 72 and rod-shaped crossjoints 73 are connected to hold conveyor frame members 71 rigidly inposition parallel to each other. Plate-shaped cross joints 72 areaffixed between conveyor frame members 71 near the center of containerconveyor 24. First and second auxiliary frame members 74 are mountedparallel to the conveying direction between conveyor frame members 71alongside bottom plate elevator 25. Rod-shaped cross joints 73 are nearthe ends of conveyor 24, where no auxiliary frame members are mountedbetween conveyor frame members 71.

A first set of short rollers 78 are rotatably mounted between oneconveyor frame member 71 and its adjacent auxiliary frame member 74.Similarly, a second set of short rollers 78 are rotatably mountedbetween the other conveyor frame member 71 and its adjacent auxiliaryframe member 74. Short rollers 78 support the edges of a container (notshown in FIG. 6) as it passes over bottom plate elevator 25. Both setsof short rollers 78 are preferably driven by contact with the upper runof a V-belt (not shown).

Returning momentarily to FIG. 5, in order to drive both sets of shortrollers 78, V-belt 80, shown in the figure, is preferably duplicated atthe opposite side of container conveyor 24.

Referring to FIG. 7, container 11 has a frame 12 and a bottom plate 13.Frame 12 is open at a top end and a bottom end. Bottom plate 13 ismovable vertically within frame 12.

Frame 12 includes a pair of side plates 14a and a pair of end plates14b. Frame components 15 surround side plates 14a and end plates 14b andconnect them to each other. Frame components 15, side plates 14a, andend plates 14b form a rectangular opening at the top end and the bottomend of frame 12. A rim cushion 16, made of a soft, pliable material suchas, for example, a sponge or foam rubber, pads the inner surface at thetop end of frame 12. A bottom frame 17 for receiving bottom plate 13 isattached to the lower part of each end plate 14b.

FIG. 8 shows the exterior side of container 11.

Referring to FIG. 9, bottom plate 13 rests in frame 12 on bottom frame17. Bottom plate 13 is free to move up and down within frame 12. Abottom cushion 18, made of a soft, pliable material such as, forexample, a sponge or foam rubber, is attached to an upper surface ofbottom plate 13. Fitting portions 19, which corresponds to bottom frames17, are attached to the underside of bottom plate 13.

Referring again to FIG. 5, the process of loading objects using objectloading device 100 starts when first detecting means 95a, mountedimmediately behind the object receiving position, detects that acontainer 11 is being moved toward the object receiving position.Actuation of downstream air cylinder 89 then causes downstream stopper88 to project above the container conveying surface, preventing forwardmovement of container 11 from the object receiving position underneathhopper 23. When second detecting means 95b, at the downstream side ofthe object receiving position, detects the presence of container 11 atthe object receiving position (when the forward side of container 11 isflush against downstream stopper 88), upstream air cylinder 93 actuates,rotating upstream stopper 90 to the up position, above the containerconveying surface, so that container 11 is held at the object receivingposition between downstream stopper 88 and upstream stopper 90.

After first detecting means 95a, behind the object receiving position,detects that container 11 (the first container) has passed, and itslocation is clear, next container air cylinder 87 is actuated to projectnext container stopper 86 above the container conveying surface. Nextcontainer stopper 86 holds back a second container 30, followingcontainer 11. Second container 30 is prevented from abutting andinterfering with container 11 which is being held in the objectreceiving position.

After first container 11 is secured at the object receiving position,elevator air cylinder 102 of bottom plate elevator 25 raises elevatingboard 101. Elevating board 101 urges bottom plate 13 of container 11upward until bottom plate 13 is raised to a position near the top ofcontainer 11.

Referring again to FIG. 2, conveyor 21 conveys and discharges objects A(not shown in FIG. 2) into hopper 23. Objects A pass through chute 55until they come to rest on shutters 22 that block the bottom of hopper23. At that time, objects A are moved onto shutters 22 with a minimaldrop impact, because they pass through inclined portion 34b of conveyor21 and inclined chute 55 before reaching shutters 22, which are alsoinclined. Since hopper cushion 54 and shutter plate cushion 64 arerespectively attached to the inner surface of hopper 23 and the uppersurface of shutters 22, the impact on objects A is further reduced by abuffer effect of hopper cushion 54 and shutter plate cushion 64.

Referring again to FIG. 3, when all of objects A to be loaded intocontainer 11 are in position on shutters 22, shutter air cylinder 67actuates opening the pair of shutters 22. Objects A on shutters 22 falla short distance onto bottom plate 13 of container 11, which has beenraised to a position closely below the bottom surface of shutters 22.The impact of objects A falling onto bottom plate 13 or objects A whichare already on bottom plate 13 is very small because of the shortdistance they fall. Therefore, the impact on objects A is greatlyreduced compared to the prior art.

After shutters 22 release objects A, elevator air cylinder 102 of bottomplate elevator 25 is actuated to lower elevating board 101, therebylowering bottom plate 13 to the bottom of container 11.

Shutter air cylinder 67 actuates again to close shutters 22 inpreparation for the beginning of the next loading cycle.

Referring to FIG. 5, upstream air cylinder 93 of container conveyor 24rotates upstream stopper 90 to the down position, thereby moving itbelow the container conveying surface. Downstream air cylinder 89 andnext container air cylinder 87 subsequently lower downstream stopper 88and next container stopper 86 below the container conveying surface.Endless belt 80 moves first container 11 downstream while secondcontainer 30 that is to be the next to receive a load of objects A iscarried toward the object receiving position.

As described above, objects A discharged from conveyor 21 come to reston shutters 22 at the bottom of hopper 23 so that objects A are releasedfor a very short fall when shutters 22 are opened. Thus, according tothe configuration of the embodiment, objects are gently loaded intocontainer 11. Furthermore, because bottom plate 13 of container 11,positioned below hopper 23, is raised by elevator air cylinder 102 toreceive objects A, the drop of objects A from shutter 22 to bottom plate13 of container 11 is short. Therefore, the impact of objects A onbottom plate 13 and/or with other objects A that are already on bottomplate 13 is reduced. Consequently, the invention protects objects A fromdents and tears, when objects A are boxes or other paper and cardboardcontainers, and breakage when they are bottles or other glass andplastic containers.

Although in the preferred embodiment, shutters 22 are shown as twoshutters which laterally open or close. The invention is not limited tothat configuration. Other configurations, such as a single shutter whichopens and closes or four shutters which slide or rotate in fourdirections to drop objects A into the center of container 11 may also beused. In addition, the shutters may be slidably, rotatably, or hingablyconnected. Such embodiments should be considered to fall within thescope and spirit of the invention.

Instead of air cylinders, an embodiment of the invention is contemplatedin which electric solenoids are employed to move the holders and theelevating means. Another embodiment of the invention is contemplated inwhich small electric motors are employed to move the holders and theelevating means. Such embodiments should be considered to fall withinthe scope and spirit of the invention.

Referring to FIG. 10, a second embodiment of the present inventionincludes a hopper 23 mounted at a forward end of the object conveyingpath of an object conveyor 21. A first buffer rotor 111a and a secondbuffer rotor 111b are mounted on an inner bottom surface of hopper 23.

First buffer rotor 111a and second buffer rotor 111b include a firstcylindrical portion 113a and a second cylindrical portion 113b,respectively. First and second cylindrical portions 113a and 113b havefirst and second supporting shafts 112a and 112b along longitudinal axesthereof and projecting from both ends thereof, respectively. First andsecond resin brushes 114a and 114b, serving as buffer portions, orcushions, are formed around the outer cylindrical surface of first andsecond cylindrical portions 113a and 113b. First and second resinbrushes 114a and 114b have bristles which project outward. The bristlesof second resin brush 114b are longer than those of first resin brush114a.

First buffer rotor 111a is mounted nearest the end of conveyor 21, at alocation lower than the conveying surface of conveyor 21. First bufferrotor 111a extends parallel to the end of conveyor 21 and is rotatablysupported by first supporting shaft 112a. First supporting shaft 112a isrotatably supported by hopper 23. Second buffer rotor 111b is mounted asufficient distance forward from first buffer rotor 111a so that objectsA may pass between first and second buffer rotors 111a and 111b. Secondbuffer rotor 111b is supported by its second supporting shaft 112b, alsorotatably supported by hopper 23.

Objects A pass between first buffer rotor 111a and second buffer rotor111b and fall into container 11. Container 11 is conveyed to a positionunderneath hopper 23 by a container conveyor 24.

Referring to FIG. 11, container conveyor 24 for conveying containers 11to a position underneath hopper 23 extends perpendicularly to objectconveyor 21.

With the above configuration, object conveyor 21 conveys objects A fromthe end of conveyor 21 into hopper 23 when objects A reach the forwardend of conveyor 21. As objects A are discharged from conveyor 21,contact first buffer rotor 111a and second buffer rotor 111b. First andsecond buffer rotors 111a and 111b absorb the force with which theobjects have been discharged, thus acting as a buffer or cushion.Objects A gently drop into container 11 in the manner of a free fall,after passing through first and second buffer rotors 111a and 111b.

This second embodiment, may also include a bottom plate 13 of container11 raisable to receive objects A. As in the first embodiment, thisreduces the drop distance of objects A from hopper 23 to bottom plate 13of container 11 so that objects A are protected from damage andbreakage.

In the second embodiment, first and second buffers rotor 111a and 111bare brushes. However, any other suitable cushioning materials, such assponge or foam rubber materials are also applicable.

In both embodiments described above, the object conveyor is a beltconveyor. However, other devices such as, for example, a rollerconveyor, a chute, a roller chute and so forth may also be used.

Having described the preferred embodiments of the invention withreference to the accompanying drawings, it is to be understood that theinvention is not limited to those precise embodiments, and that variouschanges and modification may be effected therein by one skilled in theart without departing from the scope or spirit of the invention asdefined in the appended claims.

What is claimed is:
 1. An object loading device for loading objects intocontainers with an open top, comprising:an object conveyor; a hopper atan end of said object conveyor; said hopper receiving objects conveyedby said object conveyor; at least one flap movably mounted on a bottomportion of said hopper; said flap being moveable between a closedposition and an open position to selectively hold and release saidobjects in said hopper, respectively; and means for positioning acontainer below said hopper to receive said objects.
 2. The objectloading device of claim 1, wherein at least one flap includes aplurality of flaps.
 3. The object loading device of claim 1 wherein saidmeans for positioning includes a container conveyor.
 4. The objectloading device of claim 2 wherein said plurality of flaps are slidablymounted on said bottom portion of said hopper.
 5. The object loadingdevice of claim 1, wherein said hopper further includes a cushioningmaterial on interior surfaces thereof.
 6. The object loading device ofclaim 1, wherein;said containers have a bottom plate; and said means forpositioning includes means for moving said bottom plate upward anddownward within said container.
 7. The object loading device of claim 6,wherein interior surfaces of said containers are made of a cushioningmaterial.
 8. The object loading device of claim 1, wherein inner wallsurfaces and bottom plates of said containers include a cushioningmaterial.
 9. The object loading device of claim I wherein:said at leastone flap includes a plurality of flaps; and means for moving saidplurality of flaps away from each other to permit said objects to droptherepast into said container.
 10. The object loading device of claim 1wherein said at least one flap is slidably mounted on said bottomportion of said hopper.
 11. An object loading device for loading objectsinto a container having an open top, comprising:an object conveyor; ahopper mounted at an end of said object conveyor; said hopper receivingobjects conveyed by said object conveyor; a first roller and a secondroller rotatably supported along a bottom of said hopper; said firstroller and said second roller having a cushioning material on exteriorsurfaces of said first and said second rollers; a distance between saidfirst and second rollers being large enough for said objects to passbetween them; and a container conveyor.
 12. The object loading device ofclaim 11, wherein said cushioning material is made of bristles.
 13. Theobject loading device of claim 12, wherein said hopper further includesa cushioning material on interior surfaces of said hopper.
 14. Theobject loading device of claim 11, wherein said hopper further includesa cushioning material on interior surfaces of said hopper.
 15. Theobject loading device of claim 11, wherein;said containers include abottom plate which is moveable in an upward direction within saidcontainer; and said container conveyor includes a bottom plate lifter,which pushes said bottom plate toward said hopper, at a positionunderneath said hopper.
 16. The object loading device of claim 15,wherein interior surfaces of said containers are made of a cushioningmaterial.
 17. The object loading device of claim 11, wherein interiorsurfaces of said containers are made of a cushioning material.
 18. Theobject loading device of claim 11, wherein said first and second rollersare mounted parallel to each other and perpendicular to a conveying pathof said object conveyor.
 19. An object loading device for loadingobjects into containers having a moveable bottom plate and an open top,comprising:an object conveyor; a hopper mounted at a forward end of saidobject conveyor; said hopper receiving objects conveyed by said objectconveyor; a container conveyor; means for holding a container on saidcontainer conveyor in a receiving position aligned below said hopper;and a lifting mechanism which lifts said moveable bottom plate towardsaid hopper when said container is in said position aligned below saidhopper.
 20. The object loading device of claim 19, wherein interiorsurfaces of said hopper and interior surfaces of said container are madeof a cushioning material.
 21. A method of loading objects into acontainer comprising the steps of:transporting said objects to a hopper;retaining said objects in said hopper; positioning said containerunderneath said hopper; raising a bottom plate of said container towarda raised position underneath said hopper; releasing said objects throughan opening in a bottom portion of said hopper onto said bottom plate inits raised position; lowering said bottom plate back down to a bottom ofsaid container.
 22. A method of loading objects into a containercomprising the steps of:positioning said container underneath a hopper;raising a bottom plate of said container toward said hopper;transporting objects to said hopper; transporting objects throughcushioned rollers in said hopper; and lowering said bottom plate to abottom of said container.